Welch Allyn Propaq Encore User manual

Propaq®Encore
Service Manual

Copyright © 2003 by Welch Allyn. Welch Allyn ® is a registered trademark of Welch Allyn. Propaq ® , Propaq Encore ® , and
Acuity
®
are registered trademarks of Welch Allyn. Welch Allyn is protected under various patents and patents pending.
Masimo
®
and SET
®
are registered trademarks and Signal Extraction Technology
™
is a trademark of Masimo Corporation.
NELLCOR ® , DURASENSOR ® , C-LOCK ® and OXISENSOR ® are registered trademarks of Nellcor Puritan Bennett, Inc.
LIFEPAK 5
®
and LIFEPAK 6s
®
are registered trademarks of Medtronic Physio-Control Corporation.
Copyright Notice: Software in this Product is Copyright© 2003 by Welch Allyn or its vendors. All rights are reserved. The
software is protected by United States of America copyright laws and international treaty provisions applicable all over the
world. Under such laws, you are licensed to use the copy of the software incorporated with this instrument as intended in
the operation of the product in which it is embedded, but the software may not be copied, decompiled, reverse-engineered,
disassembled or otherwise reduced to human-perceivable form. This is not a sale of the software or any copy of the
software; all right, title and ownership of the software remains with Welch Allyn or its vendors. Welch Allyn will make
available specifications necessary for interoperability of this software on request; however, users should be aware that use
of Welch Allyn hardware and software with devices or software not sold by Welch Allyn or its authorized dealers and
affiliates may lead to erroneous results and consequent danger in patient care, and may also void Welch Allyn's warranty.
Disclaimers: Welch Allyn cautions the reader of this manual:
• This manual may be wholly or partially subject to change without notice.
• All rights are reserved. No one is permitted to reproduce or duplicate, in any form, the whole or part of this manual
without permission from Welch Allyn.
•Welch Allyn will not be responsible for any injury to the user or other person(s) that may result from accidents during
operation of the Propaq monitor.
•Welch Allyn assumes no responsibility for usage not in accordance with this manual that results in illegal or improper
use of the Propaq monitor.
• No implied license: Possession or purchase of this device does not convey any express or implied license to use the
device with unauthorized sensors or cables which would, alone, or in combination with this device, fall within the scope
of one or more of the patents relating to this device.
Welch Allyn Technical Support:
For information concerning this document or any Welch Allyn product, contact:
USA 1-800-
535-6663
France ([phone] Australia ([phone]
Latin America ([phone] Germany ([phone] Singapore ([phone]
European Call Center ([phone] Canada 1-800-561-8797 Japan ([phone]
United Kingdom 0-207-365-6780 South Africa ([phone] China ([phone]
Welch Allyn
Customer Service
8500 SW Creekside Place
Beaverton, Oregon 97008-7107 USA
Within USA, toll free:
Phone: [phone]
Phone Technical Services: [phone]
WorldWide: Phone: [phone]
Fax: [phone]
Fax Technical Services: [phone]
Internet: http://www.welchallyn.com
Email Technical
Services: [e-mail]
Reorder No., Printed Manual: 810-1316-XX
Reorder No., CD: 810-1084-XX
Manual PN: 810-0696-02, Rev. A 10/03
Printed in USA
0123

Welch Allyn 3
Contents
Safety Summary
Warnings........................................................................................................ 7
Definitions ..................................................................................................... 9
Symbols ........................................................................................................ 10
Section 1
Overview
Purpose and Scope ..................................................................................... 13
Other Applicable Documents ................................................................... 13
Unpacking Procedure ................................................................................ 14
Warranty Service ........................................................................................ 14
Technical Support Services ....................................................................... 14
Recommended Service Intervals .............................................................. 15
Identifying Propaq Encore Configurations............................................. 16
Self Test and Service Menus...................................................................... 18
Section 2
Functional Verification
Introduction................................................................................................. 21
Self Tests ...............................................................................................21
Safety Tests .................................................................................................. 23
Risk (Leakage) Current Test ..............................................................23
Dielectric Strength (Hi-Pot) Test .......................................................24
Functional Verification .............................................................................. 25
Power System .......................................................................................25
System Tests .........................................................................................27
ECG/RESP Channel & Alarm Indicators ........................................28
IBP ..........................................................................................................31
NIBP ......................................................................................................32
Temperature .........................................................................................33
Functional Verification for Masimo SpO2 .......................................33
Functional Verification for Nellcor SpO2 ........................................34
Printer Tests ..........................................................................................35
CO
2
Verification Preparation .............................................................36
Mainstream CO
2
Verification Procedure .........................................40

4 Propaq Encore Service Manual
Section 3
Calibration
Introduction................................................................................................. 45
Equipment Needed..................................................................................... 46
Procedures ................................................................................................... 47
Setup ......................................................................................................47
Recharger Supply Adjustments................................................................ 48
Display Voltage Adjustments ................................................................... 50
Main Power Supply Adjustments ............................................................ 51
Calibrating Realtime ECG Out ................................................................. 54
Non-Invasive Blood Pressure Calibration............................................... 55
EMI Null Adjustment................................................................................. 56
Invasive Blood Pressure............................................................................. 56
MSP Board (MCO2) Calibration ........................................................57
Section 4
Troubleshooting
Introduction................................................................................................. 59
Screen Messages.......................................................................................... 59
Non-Recoverable Error Codes ...........................................................60
Battery Capacity Check.............................................................................. 61
Section 5
Repair Procedures
Introduction................................................................................................. 63
Propaq Encore Software ............................................................................ 63
Required Tools ............................................................................................ 64
Propaq Encore Options .......................................................................64
Field Replaceable Units in the Monitor ................................................... 65
Replacing the Power Input Fuse............................................................... 68
Replacing the Battery Pack........................................................................ 69
Removing the Single Battery Pack ....................................................70
Removing the Dual Battery in Expansion Module .........................71
Removing the Dual Battery in SpO2 Module ..................................73
Opening the Monitor.................................................................................. 73
Closing the Monitor.................................................................................... 77
Replacing the Analog Board ..................................................................... 78
Replacing the Digital Board ...................................................................... 80
Replacing the EL Display Module............................................................ 83
Removing Front Panel Buttons................................................................. 86
Replacing Recharger Board Fuse (F2)...................................................... 88
Replacing Air Tubing................................................................................. 89
Replacing the Pump ................................................................................... 95
Replacing the Side Panels.......................................................................... 96
Removing the Right Side Panel .........................................................96

Welch Allyn 5
Removing the Left Side Panel ............................................................97
Opening Expansion Module Rear Panel ........................................101
Closing Expansion Module ..............................................................102
Replacing Expansion Module Front Panel............................................ 103
Replacing Expansion Module Button Board and Buttons.................. 104
Removing Printer ..............................................................................105
Installing Printer ................................................................................106
Opening the SpO
2
Module...................................................................... 108
Replacing the SpO2 Circuit Boards........................................................ 110
Replacing the MSP/SpO
2
Circuit Boards ............................................. 111
Replacing the Sidestream CO2 Assemblies .......................................... 112
Replacing the extender board ..........................................................112
Removing the SSP/Stick board assembly: .....................................112
Replacing Expansion Module Side Panels............................................ 115
Section 6
Technical Overview
System Description................................................................................... 117
Power Electronics Description .........................................................124
Monitoring Electronics System Description ..................................126
NIBP Pneumatics Description .........................................................128
Cabling Diagrams..................................................................................... 133
Expansion Module and Printer Description......................................... 135
Pulse Oximetry Option (SpO2) Description ......................................... 137
Capnography (CO2) Description ........................................................... 140
Mainstream Board .............................................................................141
IPC Expansion ....................................................................................142
Power Distribution System ..............................................................142
CO2 Analysis Chamber (Bench) ......................................................142
Section 7
Field Replaceable Units (FRUs)
List of FRUs ............................................................................................... 143
Appendix A
Manufacturable Test Equipment
Introduction............................................................................................... 149
Appendix B
Dynatech/Nevada
Patient Simulator
Modification
Introduction............................................................................................... 151

6 Propaq Encore Service Manual

Safety Summary Warnings
Welch Allyn 7
Safety Summary
Warnings
This Safety Summary should be read by all Propaq Encore users. Specific warnings and cautions
will be found throughout the documentation where they apply.
Caution: Federal (U.S.A.) law restricts this device to sale, distribution, or use by or on the order of
a licensed medical practitioner.
Warning
Place the Propaq monitor and accessories in locations where they cannot harm the
patient if they fall from their shelf or mount. Lift the monitor only by its handle; do
not lift it by any attached cables.
Do not connect more than one patient to a monitor. Do not connect more than one
monitor to a patient.
Do not use the Propaq Encore in an MRI suite or a hyperbaric chamber.
Do not autoclave the Propaq Encore. Autoclave accessories only if the
manufacturer's instructions clearly approve it. Many accessories can be severely
damaged by autoclaving.
Inspect the power adapter cord periodically for fraying or other damage, and
replace the adapter as needed. Do not operate the apparatus from mains power with
a damaged power adapter cord or plug.
Make frequent electrical and visual checks on cables and electrode wires.
Safe interconnection between the Propaq monitor and other devices must comply
with applicable medical systems safety standards such as IEC 60601-1-1. Within
certain governmental jurisdictions, all interconnected accessory equipment must
be labeled by an approved testing laboratory. After interconnection with accessory
equipment, risk (leakage) current and grounding requirements must be maintained.
As with all medical equipment, carefully route the patient cabling to reduce the
possibility of patient entanglement or strangulation.
Avoid electrosurgery burns at monitoring sites by ensuring proper connection of
the electrosurgery return circuit so that the return paths cannot be made through
monitoring electrodes and probes.
During defibrillation, keep the discharge paddles away from ECG and other
electrodes, as well as other conductive parts in contact with the patient. Avoid
contact with any accessories connected to the Propaq’s left side panel.
To ensure patient safety, the conductive parts of the ECG electrodes (including
associated connectors) and other patient-applied parts should not contact other
conductive parts, including earth ground, at any time.

Warnings Safety Summary
8 Propaq Encore Service Manual
Warning
Do not operate this product in the presence of flammable anesthetics or other
flammable substance in combination with air, oxygen-enriched environments, or
nitrous oxide; explosion can result.
The pulse oximetry channel should NOT be used as an apnea monitor.
This monitor is to be operated by qualified personnel only. The operator of this
monitor should read this entire manual, the monitor Reference Guide or Directions
For Use , and all accessory Directions For Use before operating the monitor.
This monitor should only be repaired by qualified service personnel. The operator
should not attempt to open the monitor case or perform any maintenance on the
monitor except for procedures explicitly described in this manual that can be
performed by operators such as inspection and cleaning.
When using a power adapter with this monitor, be sure to connect the power
adapter to a three-wire, grounded, hospital-grade receptacle. Do not under any
circumstances attempt to remove the grounding conductor from the power plug of
the power adapter. Do not plug the power adapter into an extension cord. If there is
any doubt about the integrity of the protective earth ground of the receptacle for the
power adapter, do not plug in the power adapter; operate the monitor only on
battery power. Contact your biomedical engineering department for assistance in
identifying the proper power receptacle and making appropriate power
connections.
To ensure conformance to risk (leakage) current requirements when operating from
an ac mains power source, use only a Welch Allyn’ 503-0054 series power adapter.
To ensure patient safety, use only accessories recommended or supplied by Welch
Allyn. For a list of those accessories, see the Welch Allyn Products and Accessories
book that accompanied this manual (PN 810-0409-XX). Accessories must be used
according to your hospital’s standards and the manufacturer’s recommendations.
Always refer to the manufacturer’s directions for use.
A product that has been dropped or severely abused should be checked by
qualified service personnel to verify proper operation and acceptable risk (leakage)
current values.
If the monitor detects an unrecoverable problem, an error message window appears
containing an error number and a short message. Report such errors to Welch
Allyn.
The Propaq Encore should be serviced only by a Welch Allyn service technician
while under warranty.
Note
Within certain governmental jurisdictions, all interconnected accessory equipment
must be labeled by an approved testing laboratory. After interconnection with
accessory equipment, risk (leakage) current and grounding requirements must be
maintained.

Safety Summary Definitions
Welch Allyn 9
Definitions
Note
NOTE statements in the service manual, which look like this, identify information
that may be important to the reader.
Caution
CAUTION statements in the service manual, which look like this, identify
conditions or practices that could result in damage to equipment or other property.
Warning
WARNING statements in the service manual, which look like this, identify
conditions or practices that could result in personal injury.

Symbols Safety Summary
10 Propaq Encore Service Manual
Symbols
The following symbols appear in the Propaq documentation and on Propaq labels. These
internationally recognized symbols are defined by the International Electrotechnical Commission,
IEC 878 and IEC 417A.
Off (Standby). Two way communication port.
On. Input port to monitor.
For continued fire protection, use only
the specified fuse.
Signal output port from monitor.
Direct current. Alternating current.
Caution: Refer to Reference Guide and
accompanying documentation.
Temperature sensor input.
Battery charging when green indicator
illuminated.
Enclosure Protection Drip proof:
Classification IPX1 per IEC Publication
529.
All patient connections are Type CF,
isolated for direct cardiac application,
and protected against defibrillation.
For indoor use only (on power adapter
only).
All patient connections are TypeBF, and
protected against defibrillation.
Transformer meets requirements of a
short-circuit-proof safety-isolating power
transformer.
Protected during defibrillation Stacking limit by number
This way up Temperature limits
Fragile Humidity limit
Keep away from rain Altitude limit
All patient connections are TypeB Batteries must be separated from other
disposables for recycling.
The CE mark and notified body
registration number signify Propaq
Encore 200 Series monitors have met all
essential requirements of European
medical device directives 93/42/EEC.
The CE mark signifies the device has
met all essential requirements of
European Medical Device Directive 93/
42/EEC for a Class 1 product.
1
IPX1
n
n%
n
0123

Safety Summary Symbols
Welch Allyn 11
1. This symbol is on the Universal Power Adapter.
The Canadian Standards Association
has evaluated this device according to
CSA 601-1 and Underwriters Laboratory
Standard UL 2601-1.
1
This device has been tested and certified by
the Canadian Standards Association
International to comply with applicable U.S.
and Canadian medical safety standards.
Apply the NIBP cuff as shown.
Single-use only (not reusable).
NRTL/C
Evaluated to CSA 601-1
and UL2601-1
CUS
NIBP cuff sizes:
Thigh
Large adult
Adult
Small adult
Child
Infant
2

Symbols Safety Summary
12 Propaq Encore Service Manual

Section 1—Overview Purpose and Scope
Welch Allyn 13
Section 1
Overview
Purpose and Scope
The Propaq Encore Service Manual is intended as a reference for monitor maintenance and repair
to the field replaceable unit (FRU) level. FRUs are listed in Section 7. This manual provides the
technically qualified service person with troubleshooting information, repair procedures, and
calibration and performance verification instructions. A technical overview of the monitor
subsystems is provided as an introduction to the device’s circuitry and pneumatics.
Note
Configurations vary nationally. Some early versions of the Propaq Encore do not
include impedance pneumagraphy (RESP) in some countries.
This manual is intended for the technically qualified service person. Service training classes on
Welch Allyn’ products are available. Contact Welch Allyn Technical Service for information.
Other Applicable Documents
Several other documents are available for the Encore monitor. Refer to those documents for other
than maintenance and repair information. Check the Encore Reference Guide for information on
other user’s documentation.
Title Part Number
Propaq Encore Reference Guide, English 810-0640-XX
Products & Accessories Guide 810-0409-XX

Unpacking Procedure Section 1—Overview
14 Propaq Encore Service Manual
Unpacking Procedure
Use the following guidelines when unpacking the Encore monitor from its shipping carton.
1. Before opening the Encore monitor shipping carton, check it for damage.
2. If damage is apparent, stop unpacking the carton and contact the shipping company for further
instructions. If the carton is intact, unpack the Encore monitor.
3. With the Encore monitor out of its carton, check to see that all the items listed on the packing
slip (provided with shipment) are in the shipping carton.
4. If an item is missing, first recheck the carton, then check with your receiving department. If
necessary, contact Welch Allyn at the address and phone number shown below.
Note
Save the shipping carton and packing material for repacking the Encore monitor in
case it needs to be sent to a repair center or back to Welch Allyn for service.
Warranty Service
DO NOT ATTEMPT TO REPAIR the Encore monitor yourself during the warranty period. For
service and repair, contact Welch Allyn as described below.
Technical Support Services
Welch Allyn offers a wide range of technical support services including:
• 24-hour telephone support
• loaner equipment
• service contracts
• field replaceable units (FRUs)
• factory repair
For any of these services, contact Welch Allyn Technical Support at the following numbers:
Worldwide Internet Access
World Wide Web (WWW) URL: http://www.monitoring.welchallyn.com/service
World Wide E-mail: [email protected]
USA 1-800-
535-6663
France ([phone] Australia ([phone]
Latin America ([phone] Germany ([phone] Singapore ([phone]
European Call Center ([phone] Canada 1-800-561-8797 Japan ([phone]
United Kingdom 0-207-365-6780 South Africa ([phone] China ([phone]

Section 1—Overview Recommended Service Intervals
Welch Allyn 15
Recommended Service Intervals
At the intervals listed below, check the Encore monitor for normal operation.
Warning
If the monitor is opened for repair or calibration, a dielectric strength test must be
completed to ensure the integrity of the patient isolation barrier. The dielectric
strength test procedure is provided in Section 2.
Interval/Condition Perform Located in
this manual
Every 6 months to 2 years
(according to hospital protocols).
Complete risk (leakage) current
Safety Check followed by a
Functional Verification.
Section 2
If battery does not retain a
charge.
Check battery pack capacity. Section 4
Monitor is dropped or suspected
of damage or rough handling.
Complete Safety Check followed
by Functional Verification.
Section 2
Suspected malfunction with all or
part of monitoring parameters.
Functional Verification of
suspected parameter(s).
Section 2
Monitor does not pass Functional
Verification.
Calibration of monitoring
parameter circuits, or repair,
followed by Safety Check and
Functional Verification.
Section 3 and
Section 2

Identifying Propaq Encore Configurations Section 1—Overview
16 Propaq Encore Service Manual
Identifying Propaq Encore Configurations
The following table identifies Propaq monitor configurations and how they are indicated. The
model-option number and serial number are located on the back of the housing. The monitor
indicators are located under the handle on the back.
Propaq Monitor Configurations
Product
(Housing)
Model
Number
Option
Number
Parameters Included
(Acuity Option Is Also Available
With Every Model)
PROPAQ
ENCORE
MONITOR
202-EL ECG, NIBP, 2 TEMP., RESP. OPTION, EL DISPLAY
204-EL ECG, NIBP, 2 TEMP., 1 IBP, RESP. OPTION, EL DISPLAY
206-EL ECG, NIBP, 2 TEMP., 2 IBP, RESP. OPTION, EL DISPLAY
SPO2-ONLY
MODULE
210 SPO2
FOUR OPTIONS AVAILABLE:
Nellcor MP-405 (Top level assembly 007-0059-XX)
Nellcor MP-203 (Top level assembly 007-0020-XX)
Nellcor MP-507 (Top level assembly 007-0109-XX)
Masimo MS3 (Top level assembly 007-0060-XX)
EXPANSION
MODULE
See next table

Section 1—Overview Identifying Propaq Encore Configurations
Welch Allyn 17
Expansion Module Option Configurations
Option
Number Printer Mainstream
CO2
Sidestream
CO2
SpO2
Top Level
Assembly
Number
221 Yes No No N/A 007-0046-XX
222 No No No Nellcor MP-203 007-0050-XX
223 Yes No No Nellcor MP-203 007-0047-XX
223 Yes No No Nellcor MP-203 007-0051-XX
223 Yes No No Masimo MS3 007-0069-XX
223 Yes No No Nellcor MP-405 007-0086-XX
223 Yes No No Nellcor MP-507 007-0116-XX
224 No Yes No Nellcor MP-203 007-0049-XX
224 No Yes No Masimo MS3 007-0070-XX
224 No Yes No Nellcor MP-405 007-0085-XX
224 No Yes No Nellcor MP-507 007-0115-XX
225 Yes Yes No Nellcor MP-203 007-0048-XX
225 Yes Yes No Masimo MS3 007-0071-XX
225 Yes Yes No Nellcor MP-405 007-0084-XX
225 Yes Yes No Nellcor MP-507 007-0114-XX
226 No No Yes Nellcor MP-203 007-0045-XX
226 No No Yes Masimo MS3 007-0072-XX
226 No No Yes Nellcor MP-405 007-0083-XX
226 No No Yes Nellcor MP-507 007-0113-XX
227 Yes No Yes Nellcor MP-203 007-0043-XX
227 Yes No Yes Masimo MS3 007-0073-XX
227 Yes No Yes Nellcor MP-405 007-0082-XX
227 Yes No Yes Nellcor MP-507 007-0112-XX
228 No Yes Yes Nellcor MP-203 007-0052-XX
228 No Yes Yes Masimo MS3 007-0074-XX
228 No Yes Yes Nellcor MP-405 007-0081-XX
228 No Yes Yes Nellcor MP-507 007-0111-XX
229 Yes Yes Yes Nellcor MP-203 007-0044-XX
229 Yes Yes Yes Masimo MS3 007-0075-XX
229 Yes Yes Yes Nellcor MP-405 007-0080-XX
229 Yes Yes Yes Nellcor MP-507 007-0110-XX

Self Test and Service Menus Section 1—Overview
18 Propaq Encore Service Manual
Self Test and Service Menus
The Encore monitor includes built-in self-tests that verify the integrity of its hardware and
software each time you turn it on. If the monitor turns on and displays the Main Menu, all
self-tests were passed. If a self-test results in a failure, a message and error code are displayed
indicating the failure mode. Refer to Section 4 and contact Welch Allyn Technical Support for help.
The Encore monitor contains software routines that make the Functional Verification and
Calibration procedures quicker and easier. You access these routines through the Service Menus as
indicated in each of the procedures.
The figure on page 19 shows the hierarchy of the Service Menus once you enter the top level
Service Menu.

Section 1—Overview Self Test and Service Menus
Welch Allyn 19
The procedures in this manual indicate which buttons to push by separating each button menu
name with the (>) character. For example, to access the Service Menu, the procedures would
indicate for you to press SETUP > MORE > MORE > SERVICE > YES, which means you press the
SETUP button, then the MORE button, then the MORE button, then the SERVICE button, and
finally the YES button.
Note
The figure illustrates all Service Menu functions. Some of these functions are not
available if you do not have the appropriate option.
service menus
NIBP TEST IBP TEST SpO2 TST CO2 TEST MORE
PUMP TEST AUTO PMP NIBP CAL ZERO PREV MENU
MAIN CAL MAIN TEST SIDE CAL SIDE TEST PREV MENU
TEMP TEST PIXL TEST NET TST MORE
CYCLE CHECKER 1 CHECKER 2 BORDER PREV MENU
LOOP TEST OUT TEST PREV MENU
SETTINGS KEY TEST SYSTEM MORE
KEY 0 KEY 1 KEY 2 KEY 3 PREV MENU

Self Test and Service Menus Section 1—Overview
20 Propaq Encore Service Manual